Methods and systems for triggered on-loom fabric inspection

ABSTRACT

On-loom fabric inspection system ( 500 ) including an imaging device ( 522 ) configured to collect images of a weaving area ( 518 ) of a loom ( 502 ). An image-capture trigger-mechanism ( 529 ) triggers the imaging device ( 522 ) to capture images at required instants during the weaving cycle. An image processor ( 524 ) receives data from the imaging device ( 522 ) and further detects irregularities in the data.

TECHNICAL FIELD

The invention relates to systems and methods for on-loom fabricinspection. In particular, the invention relates to triggeringimage-capture devices at required instants during the weaving cycle.

BACKGROUND ART

Weaving is the most popular way of fabric manufacturing. It is primarilydone by interlacing two orthogonal sets (warp and weft) of yarns in aregular and recurring pattern. Weaving involves repeating in sequencethe operations of shedding, picking, and battening. All these processesare typically carried out by a loom. Shedding is the process by whichwarp yarns are raised or lowered to produce a space, known as the shed,through which a filler yarn may be passed. Picking is the process ofinserting a filler yarn through the shed, such that it intersects thewarp threads. Battening is the process of pressing the filler yarnagainst a fell, where the newly woven fabric is formed.

A number of faults occur in fabric during the weaving process. Wovenfabric faults include cut yarn, double yarn, hole, float, stain, etc.The quality of woven fabric depends upon the number of defects left inthe fabric after the manufacturing process. Defects developing duringany of the above-mentioned processes determine the quality of thefinished fabric. Typically, the finished fabric is inspected for faultsaccording to industry standards. For example, in the standard four-pointsystem of fabric inspection, penalty points are given for detecteddefects. The size of the penalty depends also upon the length of thedefect with 1 penalty point being given to defects of 3 inches or less,2 penalty points being given to defects of between 3 to 6 inches, 3penalty points being given to defects of between 6 to 9 inches and 4penalty points being given to defects of above 9 inches. The quality ofthe batch of cloth is described by the number of penalty points per 100yards of inspected cloth, with up to 40 points being generallyconsidered an acceptable defect rate. Apart from the four-point systemdescribed above, other standards, such as the more complicated ten-pointsystem or the Dallas System for knitted fabric, may be used to measurethe quality of cloth.

Conventionally, manual inspection is done for the finished fabric.Through manual inspection, generally, a sample size of at least tenpercent of a roll of finished fabric is inspected. Faults in uninspectedrolls are typically left undetected until the cloth is sold on.Furthermore, although such defect inspections are standardized as far aspossible, it is noted that they depend upon the subjective assessment ofthe inspector. What one inspector may consider being a defect, anotherinspector may consider being acceptable. Accordingly, the same roll ofcloth may be assessed very differently by different inspectorsregardless of its actual quality.

The use of technology has improved the way of fault detection duringvarious stages of a fabric manufacture. The highly efficient techniquesof image capturing and image analysis enable the inspection of a wovencloth in a standardized manner.

By way of example, U.S. Pat. No. 4,582,095 to Kronholm titled, “Fabricmonitoring means for power looms” describes a power loom for themanufacture of woven fabrics, which is provided with a computerizedpattern recognition system for monitoring the warp, the fabric, the edgeof the fabric, and the density of the weft. Although Kronholm's deviceincludes a video camera and computerized image processing means,Kronholm only captures images near an edge of the fabric. It isparticularly noted that Kronholm's device does not capture images of theshed region of the loom.

In another example, United States Patent Application Number 20040133297to Vergote titled, “Method for optimizing a textile production processand devices applying this method” describes a method for optimizing atextile production process by visualizing fabric-determining elements ona machine screen by means of at least one image. It is particularlynoted that Vergote's method captures images of the loom itself but failsto image the fell region or the woven fabric thereupon.

Further, United States Patent Application Number 20050031191 toVenkatachalam titled, “Methods and apparatus for inspection of linesembedded in highly textured material” describes a machine visioninspection system that is programmed and operated to identify one ormore lines appearing in a surface of a workpiece. It is particularlynoted that Venkatachalam's machine does not provide any on-loominspection but only inspects the completed fabric.

Still further, U.S. Pat. No. 6,256,091 to Kobayashi titled, “Transparentsubstrate mounting platform, transparent substrate scratch inspectiondevice, transparent substrate bevelling inspection method and device,and transparent substrate inspection method” describes a system forinspecting scratches in a crystal blank, but does not describe anyon-loom inspection of fabric manufacture.

SUMMARY OF INVENTION

In view of the limitations in the prior art, the need remains forimproved technology to detect faults through the on-loom fabricinspection system in fast and cost-effective manner. The systems andmethods described herein come to address this need.

In one aspect of the invention, an on-loom fabric inspection system ispresented comprising: at least one imaging device configured to collectimages of at least one section of a weaving area of a loom; at least oneimage-capture trigger-mechanism operable to trigger the imaging deviceto capture an image at a required instant during the weaving cycle; andat least one image processor configured and operable to receive datafrom the imaging device and further to detect irregularities in thedata.

Where appropriate, the image-capture trigger-mechanism may comprise atleast one heald-detector configured and operable to detect relativepositions of at least two heald frames of the loom. Optionally, theheald-detector comprises at least one sensor selected from the groupconsisting of: mechanical sensors, an electrical sensors, opticalsensors and combinations thereof.

Additionally or alternatively, the image-capture trigger-mechanismcomprises at least one timer operable to synchronize image capture withthe weaving cycle. Optionally, the timer comprises a stroboscope timedto expose the weaving area at the required instant in the weaving cycle.Where appropriate, the required instant coincides with the moment thatat least two heald frames are aligned. Alternatively, the requiredinstant coincides with the moment that the shed is open.

Where appropriate, the imaging device comprises a camera having anobject distance equal to the optical distance from the camera to a planeof a fell region of the weaving area. Additionally or alternatively, theimaging device comprises a camera having an object distance equal to theoptical distance from the camera to an upper warp yarn plane of a shedregion of the weaving area.

In other aspects, an on-loom fabric inspection system is disclosedcomprising an image capturing device configured to collect images of aweaving area of a loom; wherein the weaving area comprises a shedregion, a woven fabric region and a fell region. The system furthercomprises a detector to detect when heald frames are aligned with eachother and trigger the image capturing device to capture images of theweaving area at that instant. Optionally, the system also comprises atleast one image processor configured to process data pertaining to theimages and to detect irregularities in image data indicating theoccurrence of weaving faults.

Accordingly, a camera may be configured to capture images of the weavingarea when the warp yarns in the shed are coplanar with the fell regionand the newly woven fabric. This enables a single object distance to beused to image both regions allowing irregularities to be detected inboth. In certain embodiments, an image capture device is furtherconfigured to capture an image having an object plane in line with upperwarp threads of the shed and the images would be captured twice in eachcycle in order to image both sets of warp threads.

Typically, the section of the weaving area comprises all of a shedregion, a woven fabric region and a fell region.

In some examples, the on-loom fabric inspection system further comprisesan output mechanism operable to provide information to a user regardingfunctioning of the loom.

Optionally, the on-loom fabric inspection system further comprises anoutput mechanism operable to provide information selected from a groupconsisting of images, graphical representations, numbers and textpertaining to functioning of the loom.

In another aspect of the invention, a method is taught for inspectingwoven fabric. The method comprises providing at least one on-loom fabricinspection system including: at least one imaging device configured tocollect images of at least one section of a weaving area of a loom; atleast one image-capture trigger-mechanism; and at least one imageprocessor. The method further comprises steps including: selecting arequired instant during the weaving cycle; the at least oneimage-capture trigger-mechanism triggering the imaging device at therequired instant during the weaving cycle; the at least one imagingdevice capturing an image of at least one section of a weaving area atthe required instant; transferring image data to the at least one imageprocessor; and the at least one image processor analyzing the image datafor irregularities indicative of weaving faults.

Optionally, the method may also include providing a quality index for abatch of woven fabric. Additionally or alternatively, the method mayalso include adjusting the loom to correct the weaving faults. Whereappropriate, the method may also include comparing deviation ofweft-spacing in the fell region from a desired weft-spacing function.

BRIEF DESCRIPTION OF DRAWINGS

For a better understanding of the embodiments and to show how theinvention may be carried into effect, reference will now be made, purelyby way of example, to the accompanying drawings.

With specific reference now to the drawings in detail, it is stressedthat the particulars shown are by way of example and for purposes ofillustrative discussion of selected embodiments only, and are presentedin the cause of providing what is believed to be the most useful andreadily understood description of the principles and conceptual aspects.In this regard, no attempt is made to show structural details in moredetail than is necessary for a fundamental understanding; thedescription taken with the drawings making apparent to those skilled inthe art how the several selected embodiments may be put into practice.

In the accompanying drawings:

FIG. 1 illustrates a schematic side view of an exemplary configurationof an on-loom fabric inspection system integrated onto a loom;

FIG. 2 illustrates the schematic side view of the fabric inspectionsystem of FIG. 1 with an image capturing device focused to take imagesof a fell region and a newly woven fabric;

FIG. 3 illustrates the schematic side view of the fabric inspectionsystem of FIG. 1 with an image capturing device focused to take imagesof warp yarns in a shed;

FIG. 4 is a block diagram representing the main components of a firstembodiment of an on-loom fabric inspection system;

FIG. 5 illustrates a schematic side view of an exemplary configurationof an on-loom fabric inspection system of the invention;

FIG. 6 illustrates the schematic side view of the fabric inspectionsystem of FIG. 5 with an image capturing device focused to take imagesof a weaving area;

FIG. 7 is a flowchart representing a method for detecting defects inwoven fabric using the on-loom fabric inspection system; and

FIG. 8 is a representation of one frame imaged by the image capturingdevice of the on-loom fabric inspection system.

DESCRIPTION OF EMBODIMENTS

Aspects of the present disclosure relate to systems and methods foron-loom fabric inspection.

As required, detailed embodiments of the present invention are disclosedherein; however, it is to be understood that the disclosed embodimentsare merely examples of the invention that may be embodied in various andalternative forms. The figures are not necessarily to scale; somefeatures may be exaggerated or minimized to show details of particularcomponents. Therefore, specific structural and functional detailsdisclosed herein are not to be interpreted as limiting, but merely as arepresentative basis for teaching one skilled in the art to variouslyemploy the present invention.

As appropriate, in various embodiments of the disclosure, one or moretasks as described herein may be performed by a data processor, such asa computing platform or distributed computing system for executing aplurality of instructions. Optionally, the data processor includes oraccesses a volatile memory for storing instructions, data or the like.Additionally or alternatively, the data processor may access anon-volatile storage, for example, a magnetic hard disk, flash-drive,removable media or the like, for storing instructions and/or data.

It is particularly noted that the systems and methods of the disclosureherein may not be limited in its application to the details ofconstruction and the arrangement of the components or methods set forthin the description or illustrated in the drawings and examples. Thesystems and methods of the disclosure may be capable of otherembodiments, or of being practiced and carried out in various ways andtechnologies.

Alternative methods and materials similar or equivalent to thosedescribed herein may be used in the practice or testing of embodimentsof the disclosure. Nevertheless, particular methods and materials aredescribed herein for illustrative purposes only. The materials, methods,and examples are not intended to be necessarily limiting. Accordingly,various embodiments may omit, substitute, or add various procedures orcomponents as appropriate. For instance, the method steps may beperformed in an order different from described, and various steps may beadded, omitted or combined. In addition, aspects and componentsdescribed with respect to certain embodiments may be combined in variousother embodiments.

FIG. 1 represents an exemplary configuration of an on-loom fabricinspection system 100. A loom 102 includes a yarn roll 106, a take-uproll 120, a pair of heald frames 108A and 108B and a reed 110. An arrayof warp yarns 104 are threaded through the heald frames 108A and 108Band the reed 110. The heald frames 108A and 108B are made of wood ormetal such as aluminium. They carry a number of heald wires (not shown)through which the ends of the warp yarns pass. The heald frames 108A and108B are configured to raise and lower the warp yarns, thereby producinga shed 112 through which a filler yarn (not shown) may be inserted usingsome filling insertion mechanism (not shown) such as a shuttle, rapier,jet or the like. The reed 110 is a metallic comb used to batten thefiller yarn against newly woven fabric 116. It also helps to maintainthe position of the warp yarns 104. The woven fabric 116 is collected bythe take-up roll 120 as it is produced.

The on-loom fabric inspection system 100 is configured to monitor aweaving area 118 including the newly woven fabric 116, the shed 112 anda fell region 114. The fell region 114 is a section of the weaving area118 where the reed 110 strikes a weft yarn along a fell line during theoperation of the loom 102. The fell line is the boundary beyond whichthe fabric 116 has been woven. The fabric inspection system 100 includesone or more image capturing devices 122 in communication with an imageprocessor 124. Exemplary image capturing device 122 includes an analogor digital still image camera, a video camera, an optical camera, alaser camera, a laser or 3D image scanner, or any other device capableof capturing high resolution images of the weaving area 118. The imagecapturing device 122 can also be a high definition inbuilt camera of acommunication device such as a computer, a laptop or a mobile phone. Inan exemplary embodiment, to capture the images of high speed workingloom, the camera required needs to be of very high speed, for examplecapturing more than 1000 frames/second. The image processor 124 isoperable to receive and process data collected by the image capturingdevices 122. The image processor 124 can be a server computer, a clientuser computer, a personal computer (PC), a tablet PC, a laptop computer,a desktop computer, a mobile phone, a control system and a networkrouter, switch or bridge. Alternatively, the image processor 124 can besoftware application running on a virtual cloud environment. An outputmechanism 126 such as a visual display unit associated with the imageprocessor 124 may provide information to a user regarding thefunctioning of the loom 102 and upon detection of any fault. Theinformation may be provided in form of images, graphicalrepresentations, numbers or text, and can relate to measurement data,statistical data, etc. The output mechanism 126 may also display analert or a flag in case any deviation from the normal operation of theloom 102 is detected. It is noted that such a configuration of theon-loom fabric inspection system 100 may be operable to monitor theweaving area 118 during operation of the loom 102. Accordingly, acomputer may be connected to the loom 102 and operable to stop the loom102 or otherwise adjust the loom 102 settings in response to datagathered from the monitored weaving area 118.

Conventionally, the on-loom fabric inspection system 100 captures theimages of the weaving area 118 when the heald frames 108A and 108B areseparate. In such a state, since the warp yarns 112 and the fell region114 are not coplanar with each other, it is not possible to focus onboth the warp yarns 112 in the shed and the fell region 114. Therefore,the object distance of image capturing device 122 needs to be adjustedto capture images of either warp yarns 112 or the fell region 114. FIG.2 illustrates an exemplary embodiment where the image capturing device212 is focused to take images of the fell region 206 and the region 208of the newly woven fabric. In this case the image capturing device 212cannot capture the images of the warp yarns 202A, 202B in the shedregion 204. FIG. 3 illustrates another exemplary embodiment where theimage capturing device 312 is focused to take images of the warp yarns302A, 302B in the shed region 304. In this case the image capturingdevice 312 cannot capture the images of the fell region 306 and theregion 308 of the newly woven fabric.

As a remedial measure, multiple image capturing devices focused ondifferent regions 204, 206, 208 (or 304, 306, 308) may be used. However,this increases the cost and time for separate analysis of the images.

Reference is now made to the block diagram of FIG. 4, which representsthe main components of an on-loom fabric inspection system 400 accordingto the invention. The system 400 may identify faults during the processof fabric manufacture, thereby enabling early detection or prevention offabric defects. On-loom systems 400 such as described herein may serveas a cost-effective tool for providing continuous monitoring of woventextiles during production and may provide an industry standard forquality control of such fabrics.

The on-loom fabric inspection system 400 includes an image-capturetrigger-mechanism 406, an image capturing device 408, an image processor410, a controller 412 and an output mechanism 414. The image-capturetrigger-mechanism 406 is configured to trigger the image capturingdevice 408 based on a required condition. The image capturing device 408is configured to collect image data from a weaving area 402 of a loom404 and to transfer this data to the image processor 410.

Various types of image capturing device 408 may be used which suits therequirement. Exemplary image capturing device 408 includes an analog ordigital still image camera, a video camera, an optical camera, a lasercamera, a laser or 3D image scanner, or any other device capable ofcapturing high resolution images of the weaving area 402. The imagecapturing device 408 can also be a high definition inbuilt camera of acommunication device such as a computer, a laptop or a mobile phone. Inan exemplary embodiment, to capture the images of a high speed workingloom, the camera required needs to be of very high speed, like capturingmore than 1000 frames/second. Further, an array camera or the like maybe used having a resolution suitable to detect individual yarns withinwoven fabric. Resolution of the image capturing device 408 may beselected according to the cost and nature of the inspected fabric. Theresolution may be less than 1 millimeter, e.g., around 0.1 millimeter asrequired.

The image-capture trigger-mechanism 406 may include a detector or sensorconnected to the loom 404 and configured to detect the movement of healdframes 508A and 508B (shown in FIG. 5) of the loom 404. Accordingly, theimage capturing device 408 may be triggered by the detector when therequired condition is met for the heald frames. An exemplary detectormay include a mechanical sensor, an electrical sensor, or an opticalsensor. It should be noted that the scope of the invention should not belimited with the exemplary detectors described above and any otherdetector which can detect the motion of the heald frames can be used forthe purpose.

In another embodiment, the image-capture trigger-mechanism 406 mayadditionally or alternatively include a timer such as a stroboscopiclight or lamp which can be timed to produce a flash of light when therequired condition is met for the heald frames.

In still other embodiments, the image-capture trigger-mechanism 406 mayadditionally or alternatively include a receiver in communication withthe loom 404 and configured to receive output signals from an encoder ofthe loom engine. For example, a communication cable may be connectedbetween an output terminal of the loom 404 and an input terminal of theimage-capture trigger-mechanism 406. Accordingly trigger signals may besent when the required condition is met, for example the image-capturetrigger-mechanism 406 may receive a pick signal indicating that thepicking process has been initiated and the picking signal may serve as atrigger signal for the image capturing device 408.

The image data collected by the image capturing device 408 is sent tothe image processor 410 which may analyze the received image data andidentify irregularities indicative of weaving faults. Various imageprocessors 410 may be used with the system 400. A processor, such as acomputer, a field programmable gate array (FPGA), an applicationspecific integrated circuit and a microprocessor may be selected toprovide image processing at sufficiently fast rate. The processing ratemay be fast enough to allow each frame imaged by the image capturingdevice 408 to be analyzed in real time. Optionally, the image processor410 may be operable to segment each frame and to analyze each framesegment separately and possibly with individual sampling rates.Exemplary image processor 410 includes a server computer, a client usercomputer, a personal computer (PC), a tablet PC, a laptop computer, adesktop computer, a mobile phone, a control system and a network router,switch or bridge. Alternatively, the image processor 410 can be asoftware application running on a virtual cloud environment.

The controller 412 is provided to respond to the detection of weavingfaults. The controller 412 may respond, for example, by outputting datato the output mechanism 414. The output mechanism 414 such as a visualdisplay unit associated with the image processor 124 may provideinformation to a user regarding the functioning of the loom 102 and upondetection of any fault. The information may be provided in form ofimages, graphical representations, numbers or text, and can relate tomeasurement data, statistical data, etc. The output mechanism 414 mayalso display an alert or a flag in case any deviation from the normaloperation of the loom 404 is detected. The output mechanism 414 may alsocomprise a database to store the processed data of images. Whererequired, the controller 412 may be further operable to activate anoverride switch 416 to stop or otherwise adjust the loom 404 in responseto the detection of defects. The override switch 416 may be an actuatoror any other system which suits the requirement.

In one of the embodiments of the present invention, the image-capturetrigger-mechanism 406 is conditioned to trigger the image capturingdevice 408 when the heald frames 508A and 508B (shown in FIG. 5) arealigned with each other and trigger the image capturing device 408 atthat instance to capture images of the weaving area 402. In such asituation, the warp yarns in the shed are coplanar with the fell regionand the newly woven fabric.

Reference is now made to FIG. 5 which shows a schematic side view of anexemplary configuration of a fabric inspection system 500 according tothe invention, integrated onto a loom 502.

The on-loom fabric inspection system 500 includes an imaging device 522,an image-capture trigger-mechanism 529, an image processor 524,optionally a detector 528 and an output mechanism 526. The image-capturetrigger-mechanism 529 is configured and operable to trigger said imagingdevice 522 to capture an image at a required instant during the weavingcycle, and the image processor 524 is configured and operable to receivedata from said imaging device 522 and further to detect irregularitiesin said data.

The configuration of the loom 502 of FIG. 5 is similar to FIG. 1 withthe exception that the heald frames 508A and 508B are depicted at thesame level and aligned with each other. Upper and lower warp yarns in ashed 512 are in the same plane as a fell region 514 of a cloth and anewly woven fabric 516. The capturing of images of weaving area 518enables a single object distance of image capturing device 522 to beused to image both regions, the shed region 512 and the fell region 514,allowing irregularities to be detected in both. A detector 528 isincluded in the system 500 for the purpose. Preferably, in each movementcycle (up and down) of the heald frames 508A and 508B, the images ofweaving area 518 are captured twice in order to capture both sets ofwarp yarns. The detector 528 may variously comprise a sensor such as amechanical sensor, an electrical sensor, an optical sensor and the like,as well as combinations thereof.

FIG. 6A illustrates the schematic side view of a fabric inspectionsystem 600 with an image capturing device 612 focused to take images ofa weaving area 614. Since upper and lower warp yarns in shed 604 are insame plane as fell region 606 and newly woven fabric 608, the imagecapturing device 612 can use a single depth of focus over a wide angle610 to capture the image of the complete weaving area 614.

FIG. 6B illustrates another configuration of the fabric inspectionsystem 600 in which the heald frames are separated so as to raise theupper warp yarns 602A and lower the lower warp yarns 604B, therebycreating the shed. It is particularly noted that where appropriate,images may be additionally or alternatively captured in thisconfiguration. Accordingly, the image capturing device 612 may imageonly the upper warp yarns 602A, thereby enabling the image processor 410(shown in FIG. 4) to distinguish more readily between warp-risers andwarp-sinkers along the fell-pick yarn.

Referring back to FIG. 5, in still another alternative embodiment, animage-capture trigger-mechanism 529 may optionally trigger the imagecapturing device 522 in other ways. For example, an image-capturetrigger-mechanism 529 may include a timer 527 such that the shutter ofthe image capturing device 522 can be set for a fixed time to captureimages of the weaving area 518. The shutter timing can be set to theinstance when the heald frames 508A and 508B are aligned with eachother. The images of the weaving area 518 are captured at that instancewithout the need for being triggered by the detector 528.

Additionally or alternatively, the image-capture trigger-mechanism 529may further include a receiver 523 in communication with the loom 502and configured to receive output signals from an encoder of the loomengine 503.

Reference is now made to the flowchart of FIG. 7, which illustratesexemplary method steps of an embodiment of the present invention fordetecting defects in a woven fabric using the on-loom fabric inspectionsystem 500 (shown in FIG. 5).

The on-loom fabric inspection system 500 is provided at step 702. Duringthe operation of the loom 502, optionally, at step 704, an image-capturetrigger-mechanism 529, which may include a detector 528, may monitor theposition of the heald frames 508A and 508B. The image capturing device522 is triggered at a required point in the cycle, for example when theheald frames 508A and 508B are aligned with each other, at step 706. Theimage capturing device 522 then collects images of the weaving area 518,including the shed 512, the fell region 514 and the newly woven fabric516, at step 708. Image data is transferred to the image processor 524at step 710. The image processor 524 analyzes the received image datafor irregularities and faults at step 712. If an irregularity detectedin the image data indicates at step 714 that a weaving fault hasoccurred, then this fault is recorded on the output mechanism 526 atstep 716. The process may continue by another image being collected andanalyzed, such that the process may be repeated.

It is noted that the recordation of the weaving fault may involve asimple fault count such as using a penalty point system such as thefour-point for example. Alternatively more precise data relating to thetypes of faults detected and their statistical distribution for examplemay be recorded.

FIG. 8 shows the representation of one frame 800 of a weaving area 808imaged by the image capturing device 522 of the on-loom fabricinspection system 500 (cf. FIG. 5). The frame 800 shows the shed 802,the fell region 804 and the newly woven fabric 806. An oil spot, causedby a soiled section 810 propagating along the newly woven fabric 806 isalso shown. The image frame 800 is processed by the image processor 524to detect the soiled section 810 and appropriate measure can be taken bya loom operator to resolve the issue.

Weaving faults may occur in any of these areas of the frame 800 and maybe detected using the on-loom fabric inspection system 500. For example,slubs, missing yarns, end outs and the like may be detected in the shed802 and fell region 804 whereas oil spots, loom stop marks, start marksand the like may be detected in the newly woven fabric 806.

Various faults occurring in the weaving area 808 during manufacture maycause defects in the finished fabric. These include slubs, holes,missing yarns, yarn variation, end out, soiled yarns, wrong yarn faults,oil spots, loom-stop marks, start marks, thin place, smash marks, openreed, mixed filling, kinky filling, mixed end, knots, jerk-in, droppedpicks, broken picks, double picks, double ends, drawbacks, burl marksand the like. It should be noted that the listed faults are exemplary innature and should not limit the scope of the invention.

Technical and scientific terms used herein should have the same meaningas commonly understood by one of ordinary skill in the art to which thedisclosure pertains. Nevertheless, it is expected that during the lifeof a patent maturing from this application many relevant systems andmethods will be developed. Accordingly, the scope of the terms such ascomputing unit, network, display, memory, server and the like intendedto include all such new technologies a priori.

The terms “comprises”, “comprising”, “includes”, “including”, “having”and their conjugates as used herein mean “including but not limited to”and indicate that the components listed are included, but not generallyto the exclusion of other components. Such terms encompass the terms“consisting of” and “consisting essentially of”.

As used in this specification, the singular indefinite articles “a”,“an”, and the definite article “the” should be considered to include orotherwise cover both single and plural referents unless the contentclearly dictates otherwise. In other words, these articles areapplicable to one or more referents. For example, the term “a compound”or “at least one compound” may include a plurality of compounds,including mixtures thereof. As used in this specification, the term “or”is generally employed to include or otherwise cover “and/or” unless thecontent clearly dictates otherwise.

The word “exemplary” is used herein to mean “serving as an example,instance or illustration”. Any embodiment described as “exemplary” isnot necessarily to be construed as preferred or advantageous over otherembodiments or to exclude the incorporation of features from otherembodiments.

The word “optionally” is used herein to mean “is provided in someembodiments and not provided in other embodiments”. Any particularembodiment of the disclosure may include a plurality of “optional”features unless such features conflict.

It is appreciated that certain features of the invention, which are, forclarity, described in the context of separate embodiments, may also beprovided in combination in a single embodiment. Conversely, variousfeatures of the disclosure, which are, for brevity, described in thecontext of a single embodiment, may also be provided separately or inany suitable sub-combination or as suitable in any other describedembodiment of the disclosure. Certain features described in the contextof various embodiments are not to be considered essential features ofthose embodiments, unless the embodiment is inoperative without thoseelements.

Although the invention has been described in conjunction with specificembodiments thereof, it is evident that other alternatives,modifications, variations and equivalents will be apparent to thoseskilled in the art. Accordingly, it is intended to embrace all suchalternatives, modifications, variations and equivalents that fall withinthe spirit of the invention and the broad scope of the appended claims.Additionally, the various embodiments set forth hereinabove aredescribed in terms of exemplary block diagrams, flow charts and otherillustrations. As will be apparent to those of ordinary skill in theart, the illustrated embodiments and their various alternatives may beimplemented without confinement to the illustrated examples. Forexample, a block diagram and the accompanying description should not beconstrued as mandating a particular architecture, layout orconfiguration.

The presence of broadening words and phrases such as “one or more,” “atleast,” “but not limited to” or other like phrases in some instancesshall not be read to mean that the narrower case is intended or requiredin instances where such broadening phrases may be absent.

Furthermore, embodiments may be implemented by hardware, software,firmware, middleware, microcode, hardware description languages, or anycombination thereof. When implemented in software, firmware, middlewareor microcode, the program code or code segments to perform the necessarytasks may be stored in a computer-readable medium such as a storagemedium. Processors may perform the necessary tasks.

All publications, patents and patent applications mentioned in thisspecification are herein incorporated in their entirety by referenceinto the specification, to the same extent as if each individualpublication, patent or patent application was specifically andindividually indicated to be incorporated herein by reference. Inaddition, citation or identification of any reference in thisapplication shall not be construed as an admission that such referenceis available as prior art to the present disclosure. To the extent thatsection headings are used, they should not be construed as necessarilylimiting. The scope of the disclosed subject matter is defined by theappended claims and includes both combinations and sub combinations ofthe various features described hereinabove as well as variations andmodifications thereof, which would occur to persons skilled in the artupon reading the foregoing description.

1. An on-loom fabric inspection system (500) comprising: at least oneimaging device (522) configured to collect images of at least onesection of a weaving area (518) of a loom (502); at least oneimage-capture trigger-mechanism (529) operable to trigger said imagingdevice (522) to capture an image at a required instant during theweaving cycle; and at least one image processor (524) configured andoperable to receive data from said imaging device (522) and further todetect irregularities in said data, wherein said image-capturetrigger-mechanism (529) comprises at least one heald detector (528)configured and operable to detect relative positions of at least twoheald frames (508A, 508B) of said loom (502).
 2. (canceled)
 3. Theon-loom fabric inspection system of claim 1 wherein said heald detector(528) comprises at least one sensor selected from the group consistingof: mechanical sensors, electrical sensors, optical sensors andcombinations thereof.
 4. The on-loom fabric inspection system of claim 1wherein said image-capture trigger-mechanism (529) comprises at leastone timer (527) operable to synchronize image capture with said weavingcycle.
 5. The on-loom fabric inspection system of claim 4 wherein saidtimer (527) comprises a stroboscope timed to expose the weaving area atthe required instant in the weaving cycle.
 6. The on-loom fabricinspection system of claim 1 wherein said image-capturetrigger-mechanism (529) comprises at least one receiver (523) operableto receive output signals from the loom (502).
 7. The on-loom fabricinspection system of claim 1 wherein said required instant coincideswith the moment that at least two heald frames (508A, 508B) are aligned.8. The on-loom fabric inspection system of claim 1 wherein said requiredinstant coincides with the moment that the shed (112) is open.
 9. Theon-loom fabric inspection system of claim 1 wherein said imaging device(522) comprises a camera having an object distance equal to the opticaldistance from said camera to a plane of a fell region (514) of saidweaving area (518).
 10. The on-loom fabric inspection system of claim 1wherein said imaging device (612) comprises a camera having an objectdistance equal to the optical distance from said camera to an upper warpyarn (602A) plane of a shed region (604) of said weaving area (614). 11.The on-loom fabric inspection system of claim 1 wherein said section ofthe weaving area (518) comprises all of a shed region (512), a wovenfabric region (516) and a fell region (514).
 12. The on-loom fabricinspection system of claim 1 further comprising an output mechanism(526) operable to provide information to a user regarding functioning ofthe loom (502).
 13. The on-loom fabric inspection system of claim 1further comprising an output mechanism (526) operable to provideinformation selected from a group consisting of images, graphicalrepresentations, numbers or text pertaining to functioning of the loom(502).
 14. A method for inspecting woven fabric comprising: providing atleast an on-loom fabric inspection system (500) including: at least oneimaging device (522) configured to collect images of at least onesection of a weaving area (518) of a loom; at least one image-capturetrigger-mechanism (529) comprising at least one heald detector (528);and at least one image processor (524); selecting a required instantduring the weaving cycle; said at least one heald detector (528)detecting relative positions of at least two heald frames (508A, 508B)of said loom (502); said at least one image-capture trigger-mechanism(529) triggering said imaging device (522) at said required instantduring the weaving cycle; said at least one imaging device (522)capturing an image of at least one section of a weaving area (518) atsaid required instant; transferring image data to said at least oneimage processor (524); and said at least one image processor (524)analyzing said image data for irregularities indicative of weavingfaults.
 15. The method of claim 14 further comprising providing aquality index for a batch of woven fabric (520).
 16. The method of claim14 further comprising adjusting said loom (502) to correct said weavingfaults.
 17. The method of claim 14 further comparing deviation ofweft-spacing in the fell region (514) from a desired weft-spacingfunction.
 18. The method of claim 14 further comprising said healddetector (528) detecting that at least two heald frames (508A, 508B) arealigned.
 19. The method of claim 14 further comprising said healddetector (528) detecting that at least two heald frames (508A, 508B) areseparate, indicating that the shed region (512) is open.
 20. The methodof claim 14 wherein said required instant coincides with the moment thatat least two heald frames (508A, 508B) are aligned.
 21. The method ofclaim 14 wherein said required instant coincides with the moment thatthe shed region (512) is open.